Hi, I was wondering if anyone can give me some advice on whether it is safe to weld a cracked Hobie 16 mast. I was told by a dealer that it was caused by water freezing in the mast as it lay on the boat. It is a vertical crack about 5" long. Thanks

What kind of a crack and how did it crack? Aluminum weld creates a more brittle area than the substrate and tends to concentrate the stress at the weld instead of dispersing it as the mast is designed. If you have a stress fracture, a crack will develop along the weld. As stated earlier, down low, likely not an issue, but up higher with the mast bend, you're likely to have a failure along the same line. I've seen it many times in aluminum trailers, I can't see why the mast would behave differently.

That being said, a 5" vertical crack, a foot below the hounds (that the proper term for the standing rigging attachment point) could probably be successfully welded by an experienced welder who can control the heat to minimize the HAZ. You really have nothing to lose.

I'd certainly keep an eye on it afterward to make sure the crack doesn't reappear or some strange deformation doesn't develop.

Years ago I bought a H16 that had pitch poled in shallow water and broke the comp tip out of the aluminum extrusion. In the process it cracked the mast about four or five inches at this point. It was welded and I sailed the boat for years with no problem. You really have nothing to lose (unless you are three or four miles off shore and it breaks again ).

That being said, a 5" vertical crack, a foot below the hounds (that the proper term for the standing rigging attachment point) could probably be successfully welded by an experienced welder who can control the heat to minimize the HAZ. You really have nothing to lose.

I'd certainly keep an eye on it afterward to make sure the crack doesn't reappear or some strange deformation doesn't develop.

Years ago I bought a H16 that had pitch poled in shallow water and broke the comp tip out of the aluminum extrusion. In the process it cracked the mast about four or five inches at this point. It was welded and I sailed the boat for years with no problem. You really have nothing to lose (unless you are three or four miles off shore and it breaks again ).

Thanks, I currently only use it for recreational sailing in light winds, so will give it a try.

What kind of a crack and how did it crack? Aluminum weld creates a more brittle area than the substrate and tends to concentrate the stress at the weld instead of dispersing it as the mast is designed. If you have a stress fracture, a crack will develop along the weld. As stated earlier, down low, likely not an issue, but up higher with the mast bend, you're likely to have a failure along the same line. I've seen it many times in aluminum trailers, I can't see why the mast would behave differently.

The crack occurred I believe when water in the mast froze & split the mast. I will take what you have said into consideration & thanks for the advice.